Casting apparatus.



H. HI DOEHLER. CASTING AYPFABATUSI APPLICATION FILED III/III. 23. I9I5.

IRI I ktain one or more movable cores.

ILMAN H. DOEHLEB, 0F BROOKLYN, NEW YORK, ASSIGNOR TG DOJEHLER Ulli) AEiTlNlEl CMPANQY, 0F BROOKLYN, NEW YORK, A. CORPORATION 0F NEW YMH.

CASTING APPARATUS.

Letonia..

'ratus and more particularly to a type thereof especially adapted for use in the art of ressuredie casting. t

asting molten metal under pressure is now` extensively practised with various alloys and metals and by means of various p apparatus. In certain classes of work, such ascasting lines of type in linotype machines, or in casting small articles, such as bullets, entirely automatic machines have been used. By automatic, I mean l machines which either operate continuously or make the casting as one of a series of operations controlled by the operator, as in linotype machines. In commercial work where large heavy dies are used, and the machine must be adapted for handling dies of different sizes and for different cast parts, automatic machines have been foundto be of no commercial value. This is particularly true where the` dies con- The time required to set adie prior to each casting operation, in relation to, and to remove the d1e from, the charging nozzle,jto draw they:

cores, and to eject the casting is much greater than Ithat required for the actual casting operation.

vWith these Conditions in mind, l have produced a machine wherein the actual charging of the di is mechanical, the mechanism employed being under the control of the operator in much the same manner as a punch ress is operated 1n sheet metal Working. 'I e mechanism'by means of which the charging of the die is accomplished and the parts of the apparatus cooperating therewith, are so constructed as to adapt the mau chine for use in deliverinP dierent volumes of metal to meet the nee s of diderent dies or molds, thus especially adapting this machine to general commerclal .Work.

t l also provide mechanical means whereby the die may be set with relation to the charg Specification of Letters Patent'.

rammed neem, mit,

Application led March 23, .1915. y Serial No. 16,3111.

ing nozzle and may be positionedl to permit the operator to open the ydie and eject the casting therefrom. t

The mechanism for charging the die, and for handling the die supports are manually controlled through entirely independent devices so that if desired the last named mechanism may be made inoperative, or dispensed with.' y

I'employ a charging mechanism adapted to deliver with each actuation of the said mechanism adeiinite predetermined quan-` tity of molten metal, sufficient for asingle casting operation only, thusinsuring not y only the proper temperature and luidltylof the metal to secure a sound, clean casting;

`but uniformit in succeeding castings. This charging mec anism embodies a main meltfrom in a manner to avoid the introduction of sediment or dross to said chamber. It is notmy intention to claim this mechanism `broadly in this application inasmuch as the invention ofthis application relates to me` chanical appliances for delivering the metal under ,pressure to the die.

p ing-pot andan auxiliary chamber fed therey ln conJunctlon with this charging mechanism, l provide means whereby the metal 1n the melting-pot may be automatically `agitated or stirred so as to secure a substantially uniform mixture with all castings made during any run of the machine. I also provide means for indicating the level of the molten metal in the melting-pot, and a conveniently accessible shield adapted to `inclose the `-die supporting mechanism and protect the `operator from possible injury y flying metal.

The invention consists primarily in a casting apparatus embodying therein a melting-y pot, a furnace about said melting-pot,` a cylinder Within said melting-pot having 'a discharge port opening outwardly ot the bottom of said melting-pot, and .an intake port within said `melting-pot said cylinder having an elongated 'bore of small dimensions, a reciprocatory piston in said cylinder adapted to normallyclose said intake port, means adapted to actuate said piston, a main power shaft, operative connections between said power shaft and said means, and manu ally'actuated controlling means whereby the said connections may he made inoperative limi Mld

or operative with relation to said hrst named @lli Q f naa-9,9 1e

means; and in such other novel features of construction and combination of arts as are hereinafter setforth and described and more particularly pointed out in the claims hereto appended.

Referring to the drawings:

Figure 1 is a perspective View from the front of, an apparatus embodying my inven# tion;

Fig. 2 is a vertical section through the melting-pot and cylinder showing a ortion of the p1ston actuating means anda so the actuating means for the agitator or stirrer;

Fig. 3 is a detail view vof the main power shaft and the operative connections between said shaft and the means for actuating the piston;

Fig. 4 is a side elevation of the die or mold supportingmechanism and the controlling means therein; and

Fig; 5 is a detail view of the controlling means for the said die supporting mechamsm.

Like letters refer to like parts throughout theseveral views.

In the embodiment of my invention shown in the accompanyino` drawings, a indicates the main frame of the machine carrying a bed-plate b toward the bottom thereof. Supported toward the top of said frame, is a melting pot c surrounded `by a furnace d, which may be of anyl desired construction. Within the melting-potc is a cylinder e having an elongated bore of Small diameter and provided with a discharge port e at the bottom thereof, said port opening outwardly of the bottom of the melting-pot c. The outer lower end of said cylinder is nished, as at e2, to form a discharge nozzle adapted to operatively engage the mg'ate of a metal die or mold, and the walls of said cylinder within the port e are outwardly flared slightly as shown at es to facilitate the removal of any metal which? after the casting operation,v may accumulate and come chilled while Within said port` The are oi' the portion e3 oi? said cylinder is merely such as to give the proper draw for removing' this metal.

"Within the melting-pot c the cylinder e is provided with an intake port f spaced away from the bottom of the said meltingM pot suiiciently to cause the metal delivered through said port to the said cylinder, be drawn from the mass ot moltennmetal in the meltingI pot at a point intermediate the top and bottom thereoi. This arrangement ot the port f prevents the sedimenty accumulated toward the bottom of the meltingpot and the oxid or other dross accumulated at the ltop of the molten metal in said pot, being included in the metal charged into said cylinder for the purpose ci? being cast.

Mounted in, and having a close sliding t with, the cylinder c a piston g having the two-told function of 'forcinof molten metal from said cylinder into the die or mold under the requisite pressure, and of controlling the volume of metal drawn from the melting-pot and delivered to the said c linder which metal constitutes a charge or a single casting operation. This piston g is adapted to be mechanically actuated from the crank shaft g through the connectlno rod g2 mounted upon the crank gs ot said shaftand pivotally connected with said piston. Preferably the piston g consists of a rod of the same diameter throughout ulthough, if desired, the upper portion of the rod may be of smaller diameter to reduce the element of friction in the actuation thereof. The melting pot c is provided with a closure head c through which the end of the'cylinder e projects, said cylinder being held in position by said closure.

The main actuating mechanism for the machine comprises a power shaft 7L having loosely mounted thereon a fly-wheel la. The said fly-wheel is adapted to be connected with the said shaft L by means of a clutch mechanism h2 similar to that ordinarily employed upon a punch press. This clutch mechanism is controlled by means of a treadle mechanism ha, the treadle h4 of which is exposed at the front of the machine where it is conveniently accessible to the operator. The said clutch mechanism h2 is operative to connect the fly-wheel 7L to the shaft h during a predetermined rotation of said wheel upon the conclusion ot which the clutch mechanism is automatically thrown out so as to permit said shaft to come to rest.

The main power shaft h is operatively connected with the crank shaft g so that when the clutch k2 is set, the piston g will be reciprocated to lirst admit molten metal to the cylinder c and then to close said cylinder and force the metal therefrominto the die or mold.

lf a machine were to beused for making a single article requiring a fixed quantity of metal, direct connection between the shafts h and g might be used but where the quantity of metal required is uncertain or variable, it is preferable to provide a differential transmission mechanism so as to permit variation in the speed of the piston g, thus controlling the quantity of metal in the charge introduced to the cylinder e through variance in the time required for a full stroke of the said piston g. In the form of the invention shown in the accompanying drawings, the connection between the main power shaft It and the crank shaft g comprises a Jfriction disk 1', carried by the shat't g and a friction wheel z" carried by the shaft h.

The Wheel e" is adjustable axially of the shaft 7L and radially of the disk z', any desired means being provided for setting said wheel in. any adjusted position upon said Mill shaft. In the form of the invention shown, I form screw threads upon the shaft hand mount thereon a traveler' 2 operatively engaging the hub of the said wheel in the` manner shown. If desired a lock nut 3 may be used for setting the traveler i2 in any position. The disk z' is also slidably mounted upon the crank shaft g by means of an angular shaft, said disk being forced toward the wheel z" by'means of screw threads u'poiiY said shaft having the feedwheel j mounted thereon, and a spring j between said wheel and the said disk. By this construction the connecting mechanism may be set to develop any desiredpressure to be used for forcing the metal from the cylinder e into the die. The diameter of the wheel 'i is substantially the same as the effective radiusof the fric- .trolled and in this manner' the volume of molten metal delivered to the cylindere may be regulated.

Most of the so-called white metal alloys, particularly those containing aluminum, require constant agitation or stirring to prevent stratification of the different metals entering' therein. To meet this requirementr I mount in the melting-pot c a stirrer lo provided with guide rods k passing through the closure c and connected by a cross-head /c2 exteriorly of said head. Said cross-head is connected by the pitman k3 with a crank gt upon the shaft g and in this manner, with each actuation of the machine, the metal is thoroughly stirred and agitated.

Positioned within the melting ot c is a float Z provided with the stems passing throughP `and movable in,-openings in the said 'closurec By this means the level of fthe metalfin the melting' pot may be determined by theoperator at all times. A visual level indicator-is desirable in a' casting apparatus having a closed to Said float may also be used ifdesired `or manually agitating or stirring the metal in the ot. p Mounted upon the bed-plate b are vertically adjustable rods mf-m disposed toward the front and the `rear of the machine. The'serods 'carry the heads rnlm-n supporting guide-rods o upon which the die supj port p and its rigging (not shown) is slid ably mounted. The rigging upon the support may take any desired form and forms no part of this invention, although means are required in all die casting apparatus to hold the parts of thedie together agalnst the heavy pressures to which the die is subjected during the casting operation. Mounted' in the frame a of the machineis a rock shaft g passing through away b in the bed plate L and operatively connected with the die support p by the arm g and the link g2, pivot-.illy connected with-said arm and said die support.

Carried by the frame a is a power shaft r having mounted loosely thereon a driving pulley i". A clutch mechanism r2 is adapted to couple lsaid pulley to said shaft, said clutch mechanism being under the control of a treadle r3 connected with said clutch b v means-of a rod r4. Said clutch is similar to the type of clutch used in an ordinary punch press being adapted with the tripping of the treadle to connect the pulley r with the shaft. r and automatically disconnect these parts upon the completion of a predetermined quantitv of rotation of the said shaft. The shaft 1' is provided with a crank `s connected by the link a with the arm Q'. By this construction after a die has been properly closed itl may be mechanically set with relation to the discharge nozzle e and may be mechanicall)- brought into position adjacent the operator. to facilitate the open ing of the die and the ejection of the casting therefrom. The details of the ejecting mechanism is not shown as such is wellknown in this art.

To accommodate the die support to dies of different thicknesses. I provide the plate a with an adjustable stop n2 adapted to en gage the rear of the die support and arrest movement thereof when the ingate of the die or mold is in the proper position relative to the discharge port e and nozzle e3. I also provide means whereby the actuating mechanism for the die support will accommodate itself to different positions'of the said die support.

In the form of the invention shown. I accomplish this result by making the link s in two sections and connecting these two sections by means of a spring 'rigging s2. By this construction when the die support comes to rest against the stop It? the actuating'mechanisin therefor will become inoperative with relation to the support..

rI`he frame a rearwardly of the bed-plate b is closed by means of adetachable shield tand the forward portion of this bed-plate is protected by means of a vertically slidable shield u. mounted upon the guide rods u and acted upon by a counter-weight u2.. These shields are designed for the purpose of preventing injury to workmen about Ithe ma* chine from hot metal which may he. squirted from between the die parts or between the die and the discharge nozzle es.

At tf, I have shown an ordinary pyrometer for indicating the temperature of molten metal in the melting-pot.

The closure c' has a port therein closed by the removable cap c2, to permit the feedmg of lngots' to the machine while .it is in operation.

The operation of the herein described ma.

A chine is substantially as follows:

Normally the diesupport p will be close to the plate nw where it may be readily opened and closed by the operator, and the piston g will berpositioned with its operative face close to the discharge port e. The fiy wheel la, and pulley k rotate continuously.

When a die has been properly cleaned and closed the operator presses the treadle r3 setting the clutch r2 so as to cause the shaft r to make one half a full rotation at which point the said clutch will be automatically released. This one-half rotation will .through the link s and spring 82 oscillate the arm q and force the die support uponthe rods o toward the back of the machine until they engage with the stop n2. The' stop will arrestil the support in position with its ingate in .communication with the discharge 'nozzle e2. lf the stop n2 be advanced so that tial rotation of the shaft is completed, the sprin s2 will yield sufficiently to permit the comp etion of this movement while the die is in the proper position. While the die is thus beingl mechanically set, the operator may lower the shield u.

i mediately upon the release of the clutch r2 the operatordepresses the treadle itt, setting the clutch h2 and causing the power to be applied to the crank shaft g during one full, or any predetermined quantity of rotation of said shaft, the effect being to impart one full upward and downward reciprocation to the piston y.

The piston g normally Vcloses the valve f in the cylinder e, thus preventing the escape of metal from the meltingpot through said cylinder, when the machine is not in operation. Upon the up-stroke of the piston, however, the valve f is opened to .admit molten metal from the melting-pot o at a point intermediate the top and bottom of the mass of metal therein, the volume of metal thus. delivered being determined by the speed of. movement of the piston,orthe interval during which said part remains open. 'Upon the return stroke of` the piston, it will force the metal which has been flowed into the cylinder e through the port e and into the die or mold at the same timey closing the port f. Upon the completion of this return stroke, the said piston will come to rest.

lt 'will be noted that the actuation of the said piston by means of4 a crank, will cause said pistoni to start at slow speed, and travel at a gradually accelerated speed for half of the upstroke, and that the completion of this stroke will be at a gradually reduced speed coming to a dead stop when the said d@ crank :is at the top center. .During the the said holder comes to rest before the par-v down-stroke there will be a gradually accelerated speed from the beginning of the stroke until the said piston has closed the port f, whereupon there will be a gradual reduction of speed during that interval when the greatest pressure is required in forcing the metal into the die. By this construction, the maximum pressure upon the metal will be the final pressure after the greater portion of the metal is in the die. This will result 1n compactness in the casting.

When the piston becomes operative upon the metal, there will be a solid mass of metal in the lower portion of the cylinder, which metal will have been accumulated by reason of the fact that the ingate of the die is constricted. Furthermore, during the applicat1on of pressure by said Piston, the metal will be flowing, or have a tendency to vflow into the die, under gravity, which also contributes 'toward compactness in the casting. The movement of the piston will have sufficient rapidity to insure the proper condition of the metal as it enters the die.

When the piston g completes its full reciprocatory movement, the treadle rs is again depressed to set the clutch r2 and cause the l shaft r to complete its rotation and bring the die support to its original position adjacent the operator, who thereupon opens the die, ejects the casting, cleans' the die and closes it again, and repeats the above operation.

It will thus be seen that the movement of the die into and out of the casting position is mechanically effected. The mechanism, however, heilig under the control of the op erator so that the effective operations of the machine may be timed in accordance with the time required by the operator to draw cores, open the die, eject the casting, clean the die and close it. It will'also be seen that the forcino' of the metal is purely mechanical, while being under the control of the op-v erator. 4

With ordinary dies, a. machine may be operated by a single man.

When the connection between the power shaft and the crank shaft g consists of friction devices as described, it is possible to 116 control not only the volume of metal introduced lto the cylinder e as a charge for each casting operation, but also the pressure under which the metal is delivered to the die. During .the up-stroke of the piston 120 there is little or no load upon the friction mechanism, so that during this up-stroke no Aslippage in the friction device will occur.

Upon the down-stroke, however, very substantial resistance is offered to the movement. of the piston and the degree of friction must be adjusted to meet this condition. The variation in the piston speed compensates in part for the gradually increasing resistance to the piston in the cylinder. By adjusting 13@ made inoperative or operative with 'relation to said ,first named means, a reciprocatory die support, power driven means adapted to Aintermittently actuate same and manually dii operative controlling means for said power mechanism 7, A casting apparatus embodyin therein a .melting1 pot, a o linder within. said melting ,pot ,.aving e ischarge port opening outwardly oi? the bottom oiseid melt'- ing pot and an intake port within-.Said .melting pot, said cylinder having an elongated here oi small dimensions, a reciprocatory piston in said cylinder adapted to normally close said intake port, means adapted to -actuate seid piston, a main power shaft, ditterentially operative connections between said power shaft and said means whereby said piston .may be aettuitedy at different speeds and manually actuated controlling means whereby the said connections may be vricade inoperative or operative with relation to said liestv named means.

8. A casting apparatus embodyin therein a melting pot, a cylinder within said melting not having a discharge ort opening outwardly ofthe bottom of ssidpmeltng pot and an intake port within said melting pot, said cylinder having an elongated bore of small dimensions, a reciprocatory piston in said cylinder' adapted to normally close said intake port, means whereby said piston is reci rocated at varying speeds with each stro re thereof, the lowest speed of said piston being at the end of the down and of the `lip-stroke, a main. power shaft, operative connections between said power shaft andv said means, and manually actuated controlling means whereby the said connections may be made inoperative or operative with relation to saidyrst named. means.. 9. A `casting apparatus embodying there,- n a meltin pot, a 'c linder within said melting` pot avin a ischarge port opening outwardly of t e bottom ol said melting pot and an intake port within sind melting pot, said cylinder having an elongated :bore of small dimensions, a reciprocatory piston in said cylinder adapted to normally close saidintake por-t, a crank shaft and a connecting rod between the said sliatand said piston whereby saidpiston is reciprocated at varying speeds with each stroke thereof, the lowest speed of said piston being at the end of ythe down and of the 11p-stroke, a main power shaft, operative. connections between seid power shaft and said crank shaft, and manually actuated controlling means whereby'the said connections may be made inoperative or operative with relation to said first named means.

10. A casting apparatus embodyin therein a melting pot, a cylinder'within said melting pot'l having dischargeeport opening outwardly of the bottom osaid melting pot recopie and m intake port within said melting pot, said cylinder having 'an elongated bore of small dimensions, a reciprocatory piston in sa1d cylinder adapted to normally close said lntake port, a crank shaft and a connecting rod between the said shaft and said piston whereby 'said iston is reciprocated at varying speeds w1th each stroke thereof, the lowest speed of said piston being at the end of the down and of the up-stroke, a main power shaft, a vfriction clutch mechanism, the )parte of which are carried by said power sha and said crank shaft respectively and manually actuated controlling means where` by said friction clutch mechanism ma be made inoperative or operative as desire l1. A casting apparatus embodying therein a melting pot, a cylinder within seid melting pot having a dischar e port opening outwardly of the bottom o said melting pot and an intake port within said melting pot, said cylinder. having an elongated bore of small dimensions, a reciprocatory piston 'in said cylinder adapted to normally close said intake port, means adapted to actuate saidl piston, a mai-n power shaft, diderentially operative connections between said power shaft and said means whereby said piston may be actuated at dierent speeds, means controllin the force applied through said piston, an manually actuated con'- trolling means whereby the said connections may be made inoperative or operative with relation .to said -first named means.

l2. A casting apparatus embodying therein a melting pot, a cylinder within said melting pot havin a discharge port opening outwardly of t e bottom o said melting pot and Van intake port within said melting pot, said cylinder having an .elongated bore of small dimensions, a reciprocatory piston in said cylinder adapted to normally close said intake port, a crank shaft and a connecting rod'between the said shaft and said piston whereby said piston is reciprocatecl at varying speeds with each stroke thereof, the lowest speed of said piston being at the end of the down and of the up-stroke, o. main power shaft, a friction clutch mechansm, the parts of which are carried by said power shat and said crank shaft respectively, regulating means whereby the power of said friction clutch may be determined and manually actuated controllin means whereby said friction clutch mechanism ma he made inoperative or operative as desire 13. A casting apparatus embodying therein a melting pot, a cylinder within said melting pot having a discharge port opening outwardly of the bottom of said melting pot and an intake port within said melting pot, said cylinder having an elongated bore of small dimensions, a reciprocatory piston in said cylinder adapted to normally close said intalreport, shaft and a connecting 130 rod between the said shaft and said piston wher-eh)v said piston is reciprocated at varying speeds with each stroke thereof, the lowest speed of said piston being at the end of the down and of the 11p-stroke, a main power shaft, operative connections between said power shaft and said crank shafta clutch mechanism whereby said connections may be made operative or inoperative, a pedal and connections between said pedal and said clutch mechanism.

.14. A casting apparatus embodying therein a melting pot, a cylinder within said melting pot having a discharge 'port open-A ing outwardly of the bottom of said melting not and an intake port withinisaid melting pot, said cylinder having an elongated bore of small dimensicns, a reci'procatory piston in said cylinder adapted to normally close saidintake port, means adapted to actuate said piston, a main power shaft, operative connections between said power shaft and said means, a stirrer located in Said melting pot and connections between said stirrer and said means actuating the piston whereby the metal in said pot will be agitated with each piston stroke and independently of said piston, and manually actuated controlling means whereby the said connections may be made inoperative or operative with relation to said first named means.

15. A casting apparatus embodying therein a melting pot, a cylinder within said melting pot having a discharge port opening outwardly of the bottom of said melting pot and an intakeport within said melting pot, said cylinder having an elongated bore of small dimensions, a reciprocatory piston in said cylinder adapted to normally close said intake port, means adapted to actuate said piston, a main power shaft, operative connections between said power shaft and said means, manually actuated controlling means whereby the said connections may be made inoperative or operative with relation to said first named means, a reciprocatory die support, a crank shaft, a driving pulley, a clutch mechanism whereby said crank shaft may be connected to said power pulley during a one half revolution thereof only, connections between the crank of said crank shaft and said die support and manually operative means controlling said clutch.

16. A casting apparatus embodying therein a melting pot, a cylinder within said melting pot having a discharge port opening outwardly of the bottom of said melting pot and an intake port within said melting pot, said cylinder having an elongatei bore of small dimensions, a reciprocatory piston in said cylinde adapted to normally close said intake port, means adapted to actuate` said piston, a main power shaft, operative connections between said power shaft and said means, manually actuated controlling meansV whereby the said connections may be made inoperative or operative with relation to said first named means, tracks extending under and below thel discharge port of said melting pot, an adjustabe stop adjacent said tracks and said portV -justable connection whereby the die maybe accurati ly positioned with relation to said port and manually operative means for controlling said yower mechanism.

' 17. Acastingl apparatus embodying therein a melting pot, a c linder within said melting pot having a ischarge port opening outwardly of the bottom of said melting pot and an intake port within said melting pot, said cylinder having an elongated bore of small dimensions, a reciprocatory piston in said cylinder adapted to normally close said intake port, means ada ted to actuate said piston, a main power s aft, operative connections between said'power shaft and said means, manually actuated controlling means whereby thesaid connections may be made'inoperative or operative with. relatiolrto said rstnamed means, tracks extending under and below the discharge port of said melting pot, an adjustable stop adjacent said tracks and said port, a movable die support mounted upon said tracks, power aetuated means adapted to reciprocate said stop including therein a yieldable connection whereby the die may be automatically and accurately positioned with relation to said port andvmanually operative means for controlling said power mechanism.

ln witness whereof, l hereunto aiiic my signature in the presence of two subscribing witnesses this 17th day of March. 1915.

HERMAN il. DEHLER.. Witnesses: y

Ui, A. Sonnononn, W. Bannascnnm'r.

titl

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